Flexo Technology
Precision in print: Why anilox consistency is key to flexo quality
Stuart Mitchell, technical director print (global OEM & sales support), Sandon Global, says that in the world of flexographic printing technology, consistency is not merely desirable – it is essential.
A
s converters face higher customer expectations, tighter colour tolerances and rising productivity targets, the demand for high-performance print components has never been greater. At the heart of this requirement is the anilox – a component whose consistency directly infl uences ink transfer accuracy and, ultimately, the quality and repeatability of the entire fl exographic process. Anilox technology is not simply about volume. What matters is the reliability and predictability of ink transfer – from the fi rst impression to the last, and across multiple jobs. Even minor deviations in cell geometry, surface fi nish or coating uniformity can result in unacceptable variation in colour density, laydown and image quality. These inconsistencies lead to increased waste, extended set-up times and dissatisfi ed brand owners. For printers aiming for excellence, anilox consistency is not a target – it is a minimum standard.
MATERIALS SCIENCE AT THE CORE Anilox performance begins with the coating – and at Sandon Global, we treat this as a scientifi c discipline. Our in-house metallurgy laboratory plays a leading role in ensuring the quality and uniformity of the substrates and ceramic coatings used in every anilox we produce. If coating quality is compromised, every subsequent stage – particularly laser engraving – is aff ected. Through advanced metallurgical analysis and precise control of porosity, hardness and corrosion resistance, we develop coatings that are robust, uniform and reliable on press.
ENGINEERED FOR CONSISTENCY Anilox engineered using fi bre glass sleeves from industry leaders including XSYS and Rossini and solid aluminium provides superior rigidity, reducing
24 June 2025
Sandon Global also manufactures anilox rollers using a combination of materials, according to the individual press manufacturer, that includes aluminium, mild steel and/or stainless steel.
TOTAL QUALITY CONTROL Sandon Global is one of the few anilox manufacturers to commit to 100% in-house production. From base manufacture and ceramic coating to laser engraving and fi nal inspection, every process is conducted under one roof at our UK headquarters.
This vertical integration provides complete control over tolerances, traceability and product integrity. It removes variability between batches and ensures printers receive consistent performance – essential for repeat jobs and colour- critical applications.
ENHANCED DENSIFICATION FOR RELIABLE INK TRANSFER
the risk of deformation and total indicated runout (TIR) issues – a deliberate investment at Sandon Global in quality that enhances long-term performance.
Our patented anilox sleeve construction (Pat. EP3368317B1 and Pat. US11059284) overcomes common structural issues such as delamination and deformation. Built to withstand the mechanical, thermal and chemical stresses of high- speed fl exo operations, our sleeves provide greater dimensional stability and durability compared to other sleeves available. Whilst some anilox sleeves in the market are slightly lighter weight, a solid cold-drawn aluminium tube, as used by Sandon Global, enables 100% adhesion of the components to minimise the risk of anilox failure. It is not just about longer lifespan. A sleeve that holds its shape ensures that cell geometry and volume remain true, delivering consistent ink transfer and reducing press variability over time. CNC-machined, hand-fi tted end rings with precision threading provide exceptional durability, while a unique gasket seal protects against chemical ingress and substrate corrosion. Together, this combination of precision- engineered end ring technology and robust base construction enhance mechanical integrity, extend sleeve life, and strengthen the return on anilox investment.
For the narrow web and corrugated sectors,
To further support consistency, Sandon Global applies a proprietary Enhanced Densifi cation Treatment (EDT) to the ceramic coating before engraving. This process densifi es and seals the chromium oxide layer, removing porosity and reducing the potential for oxidation, both of which can disrupt ink transfer and reduce anilox life. By improving surface fi nish and coating hardness, EDT allows for sharper, more uniform engravings – delivering cleaner, more consistent ink release. For printers, the result is improved colour control, quicker make-ready and greater overall effi ciency.
MEETING THE DEMANDS OF MODERN FLEXO Flexographic printing is evolving rapidly. Higher line counts, fi ner screens, complex graphics and thinner ink fi lms are now standard. Anilox performance must meet these demands with unwavering reliability.
Printers need to know that every anilox will perform exactly as expected. That’s why Sandon Global works closely with its customers, providing application-specifi c engravings, technical consultancy and root cause analysis of ink transfer issues. Our team combines deep fl exo knowledge with engineering excellence to help customers optimise performance and future-proof their operations.
CONSISTENCY: A FOUNDATION FOR PRINT EXCELLENCE In today’s fl exographic sector, consistency is more than a competitive edge – it is the bedrock of print quality, effi ciency, and customer satisfaction. By fusing advanced materials science and unique anilox engineering and technology with total in- house control, Sandon Global can deliver anilox that perform with precision – every time.
www.convertermag.com
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